Fullsac Baffles on 08 Ultra
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Stellar HDF Member
Joined: Mar 2010
Posts: 2,625
Likes: 129
From: Black River Falls, WI.
Fullsac Baffles on 08 Ultra
First step done. I found a set of CVO take of mufflers from a fello HDF member and they are on the way. I ordered my baffles just now and it was a good start to say the least. I started on line but am still not all that crazy about CC numbers on the internet and all that, plus I wanted to mention the HDF discount. The girl that answered the phone was very good. She knows the product and was happy to take my order over the phone. I had hardly hung up when i got the email from UPS with my tracking info. Great start to what I hope is a great do it yourself mod.
Outstanding HDF Member
Joined: Oct 2007
Posts: 2,398
Likes: 34
From: Newport news, Virginia
Although I have ride an '08 standard I have the Full sac true dual conversion and re-cored my CVO Touring mufflers with their 2" baffles. I also run a PC-V and Mo Flow AC. I am happy as a clam. The sound is loud but not loud enough to **** off your neighbors or give you head aches. You will enjoy them!
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Stellar HDF Member
Joined: Mar 2010
Posts: 2,625
Likes: 129
From: Black River Falls, WI.
Baffles
Although I have ride an '08 standard I have the Full sac true dual conversion and re-cored my CVO Touring mufflers with their 2" baffles. I also run a PC-V and Mo Flow AC. I am happy as a clam. The sound is loud but not loud enough to **** off your neighbors or give you head aches. You will enjoy them!
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Stellar HDF Member
Joined: Mar 2010
Posts: 2,625
Likes: 129
From: Black River Falls, WI.
CVO mufflers
Well I has a few spare minutes and decided to put on the CVO's on to listen to them before I get the fullsac's tomorrow. A little more low rumble noise, but aside from the looks there was next to no diffrence. Might even be a little quieter on hard throttle grabs. Hope to have 'em all done and on by the weekend.
Road Master
Joined: May 2008
Posts: 1,065
Likes: 1
From: Madison, WI
First step done. I found a set of CVO take of mufflers from a fello HDF member and they are on the way. I ordered my baffles just now and it was a good start to say the least. I started on line but am still not all that crazy about CC numbers on the internet and all that, plus I wanted to mention the HDF discount. The girl that answered the phone was very good. She knows the product and was happy to take my order over the phone. I had hardly hung up when i got the email from UPS with my tracking info. Great start to what I hope is a great do it yourself mod.
My plan was slightly different as I already had the Fullsac modded stockers. Those CVO muffs look cool. Keep us posted.
Tourer
Joined: Nov 2007
Posts: 313
Likes: 2
From: Ontario,Canada
I have tried others but I always go back to my fullsacs they just sound right, no blat and no decel pop
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Stellar HDF Member
Joined: Mar 2010
Posts: 2,625
Likes: 129
From: Black River Falls, WI.
Conclusion on muffler #1
Well I have learned alot about CVO slip ons and ALL of their internal parts. I took it very slow and took my time in all aspects of the baffle installation. I learned that my two mufflers were made on different days buy diffrent welders, and even with diffrent wire, I think. The first muffler came off the bike and was on the bench in minutes. I then started to cut the 2 welds that might have been 3/4 inch long with a die grinder and a fairly agresive bit. I ground weld out until I was not comfortable HOGGIN' it out any more and downshifted to the dremel tool with a few diffrent selections of bit, but learned quickly that the green stone that is shaped something like a nickle works the best of all the bits I had to choose from. Again, I took my time and watched and listened and could tell when ya go from cutting weld to cutting either baffle or muffler case. I got all the visable weld cut out going slowly and turned it so the exit end was facing the ground and gave it a few short drop like taps onto a thick padded typ of carpet and on the third hit, I heard it break free. Victory!!! 
I then cleaned all the weld spots up good and drove it out of the exit end of the can. Followed instructions on hole placement and drilled using a few diferent size bits up to the 1/4 inch hole. USE A DRILL PRESS and a few bit sizes, and a good center punch to do this. Then put the baffle in. This is something you learn as you go and if you watch thru the muffler as you are sliding it in it will drop right into place. Took a few times, but I got it good and centered, put the bolt in that holds the baffle in place, replaced the end cap and it was ready to go back on... With a few short breaks here and there, about an hour and a half or so.
I then cleaned all the weld spots up good and drove it out of the exit end of the can. Followed instructions on hole placement and drilled using a few diferent size bits up to the 1/4 inch hole. USE A DRILL PRESS and a few bit sizes, and a good center punch to do this. Then put the baffle in. This is something you learn as you go and if you watch thru the muffler as you are sliding it in it will drop right into place. Took a few times, but I got it good and centered, put the bolt in that holds the baffle in place, replaced the end cap and it was ready to go back on... With a few short breaks here and there, about an hour and a half or so.
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Thread Starter
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Stellar HDF Member
Joined: Mar 2010
Posts: 2,625
Likes: 129
From: Black River Falls, WI.
On to the 2nd muffler
I think the guy who welded this one together was an expert hard weld welder and was laughing and saying, "Someday some sucker is going to try to open this up, and I am going to make life miserable for him!" These welds were both a little better than an inch long. The outcome is the same on this muffler, but the time was more like almost 4 hours and that does not include my call to Walmart at midnight to see if they carry dremel bits, thankfully they do. So 20 minutes each way at midnight was added to the fun. I learned that if your dremel wheel gets to worn down, that the extra noise you hear is the collar on the dremel turning from a nice black painted look, to a shinny silver color in a hurry from contacting the outside edge of the muffler can. I also learned if you try to hold the tool to close the exit pipe on the stick baffle that it might just be pressing on the lock button and when you get done, the lock doesn't work nearly as well as it did before you begin. Long story short is that this sound is GREAT and if I ever do it again, I will be much more efficient, because if there was anything that could have gotten in the way on the second one, it did. Hats off to Steve at Fullsac. He makes a great product and supports it well too. The entire experience was pretty cool when ya have that sense of accomplishment on the do it yourself modification. I am glad I had another set of slip ons to keep on the bike while I worked on these. Don't do this in a hurry or if you think you can sqeeze it in in an hour. Take your time and enjoy the benefits these baffles have.
KRIS...
KRIS...
Last edited by BlackPearl#1; May 18, 2010 at 12:01 PM.
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